Non-contact surgical adapter electrical interface

ABSTRACT

A surgical instrument includes a handle, an adaptor, and a non-contact electrical interface. A proximal end of the adaptor is releasably coupled to a distal end of the handle. The non-contact electrical interface is configured to wirelessly transmit energy from the handle to the adaptor and is configured to wirelessly transmit data from the adaptor to the handle. The electrical interface may include a proximal coil disposed within the handle and a distal coil disposed within the adaptor. When the adaptor is coupled to the handle, the proximal coil may be disposed adjacent the distal coil to form a transformer to inductively transfer energy from the handle to the adaptor and inductively transmit data from the adaptor to the handle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalPatent Application No. 61/980,724, filed Apr. 17, 2014, the entiredisclosure of which is incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to surgical instruments and, morespecifically, to non-contact electrical interfaces for surgicalinstruments.

2. Discussion of Related Art

Powered surgical instruments generally have a handle portion and aworking portion extending from the handle portion that contacts apatient. The working portion may require energy to power elementsthereof and may gather data from a plurality of sensors thereof. Powermay be transferred from the handle portion to the working portion anddata may be transferred from the working portion to the handle portionthrough an electrical interface. Traditionally the electrical interfaceincludes galvanic electrical connections allowing the working portion todetach from the handle portion. After each use, the powered surgicalinstrument is disposed of, reused, or partially disposed of andpartially reused. Any part of a powered surgical instrument that isreused must be sterilized, by autoclaving, to neutralize potentiallyinfectious agents before being reused.

The autoclave process has been used for many years to sterilizedreusable surgical instruments. However, galvanic electrical connectionsare susceptible to damage from the steam and the high-pressure used inthe autoclave process. For example, during the autoclave process thegalvanic electrical connections can corrode, form dendtric growths, orelectro-plate.

Accordingly, a continuing need exists for electrical contacts that arenot susceptible to the autoclave process that can pass electrical powerand data signals between a working portion and a handle portion of asurgical instrument.

SUMMARY

In the following aspects of the present disclosure, a non-contactelectrical interface may pass power from a handle portion to a workingportion of a surgical instrument and simultaneously pass a data signalfrom the working portion to the handle portion and/or from the handleportion to the working portion.

In an aspect of the present disclosure, a surgical instrument includes ahandle, an adaptor, and a non-contact electrical interface formedtherebetween. The adaptor includes a proximal end that is releasablycoupled to a distal end of the handle. The non-contact electricalinterface is configured to wirelessly transfer energy from the handle tothe adaptor and to wirelessly transmit data from the adaptor to thehandle.

In aspects, the handle includes a protrusion and the adaptor defines arecess. The recess of the adaptor receives the protrusion of the handlewhen the adaptor is coupled to the handle. The electrical interfaceincludes a proximal electrical coil that is disposed within theprotrusion of handle and a distal electrical coil disposed within theadaptor at a location adjacent the recess. When the adaptor is coupledto the handle, the proximal and distal electrical coils may form atransformer. The proximal electrical coil may inductively transfer aconstant supply of energy to the distal electrical coil. In embodiments,an energy source is disposed within the handle that is electricallycoupled to the proximal electrical coil. In some embodiments, an energystorage device is disposed within the adapter that is electricallycoupled to the distal electrical coil. The energy storage device may beconfigured to store energy from the energy source. In certainembodiments, the electrical interface includes a signal processordisposed within the adaptor. The energy storage device may be configuredto energize the signal processor.

In some aspects, the electrical interface includes a signal processordisposed within the adaptor that is configured to transmit highfrequency signals data signals to the distal electrical coil. The energystorage device may be configured to energize a plurality of sensors.Each of the plurality of sensors may provide data signals to the signalprocessor.

In certain aspects, the electrical interface includes a control circuitthat is configured to wirelessly transmit control signals from thehandle to the adaptor. The control circuit may include a proximalcontrol coil that is disposed within the protrusion of the handle and adistal control coil disposed within the adaptor at a location adjacentto the recess. The proximal and distal control coils may form a controltransformer when the adaptor is coupled to the handle. The controltransformer may inductively transmit control signals from the handle tothe adaptor. In embodiments, the handle includes a control interface andthe electrical interface includes a processor disposed within thehandle. The processor may be configured to receive control inputs fromthe control interface and to receive data from the adaptor. Theprocessor may be configured to generate control signals from the controlinputs and from the data. The processor may transmit the control signalsto the proximal control coil.

In particular aspects, the surgical instrument includes a loading unitthat is releasably coupled to a distal end of the adaptor. The loadingunit and the adaptor form a second electrical interface. The secondelectrical interface is configured to inductively transfer energy fromthe adaptor to the loading unit and is configured to inductivelytransmit data signals from the loading unit to the adaptor.

In other aspects of the present disclosure, a method of communicationbetween components of a surgical instrument includes providing asurgical instrument including a handle and an adaptor, coupling aproximal end of the adaptor to a distal end of the handle to form anon-contact electrical interface, using the non-contact electricalinterface to wirelessly transfer energy from the handle to the adaptor,and using the non-contact electrical interface to wirelessly transmitdata from the adaptor to the handle. The surgical instrument may be anyof the surgical instruments disclosed herein.

In aspects, forming the non-contact electrical interface includespositioning a proximal coil disposed within the handle adjacent a distalcoil disposed within the adaptor to form a transformer. Wirelesslytransferring energy from the energy source may include inductivelytransferring energy across the transformer from the handle to theadaptor. Wirelessly transmitting data from the adaptor to the handle mayinclude inductively transmitting data across the transformer from theadaptor to the handle.

Further, to the extent consistent, any of the aspects described hereinmay be used in conjunction with any or all of the other aspectsdescribed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are described hereinbelow withreference to the drawings, wherein:

FIG. 1 is a perspective view of a surgical instrument provided inaccordance with the present disclosure;

FIG. 2 is an exploded view of the components of the surgical instrumentof FIG. 1;

FIG. 3 is a cross-sectional view taken along the section line 3-3 ofFIG. 1 illustrating an electrical interface between the handle and theadaptor of the instrument of FIG. 1;

FIG. 4 is a cut-away perspective view of the adaptor receiver of thehandle of FIG. 2;

FIG. 5 is an enlarged view of the area of detail of FIG. 2 illustratingthe handle connector of the adaptor of FIG. 2;

FIG. 6 is a schematic view of the electrical interface between thehandle and the adaptor of FIG. 3; and

FIG. 7 is a cross-sectional view taken along section line 7-7 of FIG. 1illustrating an electrical interface between the adaptor and the loadingunit of FIG. 1.

DETAILED DESCRIPTION

Embodiments of the present disclosure are now described in detail withreference to the drawings in which like reference numerals designateidentical or corresponding elements in each of the several views. Asused herein, the term “clinician” refers to a doctor, a nurse, or anyother care provider and may include support personnel. Throughout thisdescription, the term “proximal” refers to the portion of the device orcomponent thereof that is closest to the clinician and the term “distal”refers to the portion of the device or component thereof that isfarthest from the clinician.

Referring now to FIGS. 1-3, a surgical instrument 10 is provided inaccordance with the present disclosure including a handle 20, an adaptor30, and a disposable loading unit 40. The adaptor 30 includes a handleconnector 32 at a proximal end thereof and the handle 20 defines anadaptor receiver 26 for receiving the handle connector 32 to releasablycouple the adaptor 30 to the handle 20. The disposable loading unit 40includes a loading unit connector 42 at a proximal end thereof and theadaptor 30 defines a loading unit receiver 36 adjacent a distal endthereof to releasably couple the disposable loading unit 40 to theadaptor 30. The disposable loading unit 40 includes an end effectorassembly 140 including first and second jaw members 142, 144 that aremoveable relative to one another and are configured to act on tissue.

An exemplary embodiment of a surgical instrument is disclosed incommonly owned and co-pending U.S. patent application Ser. No.13/484,975 filed May 31, 2012, and now published as U.S. PatentPublication No. 2012/0253329 on Oct. 4, 2012 the contents of which arehereby incorporated by reference in its entirety.

With particular reference to FIG. 3, an electrical interface 50 isdisposed within the adaptor receiver 26 and the handle connector 32. Theelectrical interface 50 is a non-contact electrical interface thattransmits energy from the handle 20 to the adaptor 30 and transmits datasignals from the adaptor 30 and/or the disposable loading unit 40 to thehandle 20, between the adaptor receiver 26 and the handle connector 32,as detailed below. It is contemplated that control signals aretransmitted by the electrical interface 50 from the handle 20 to theadaptor 30. The handle 20 may include a display 25 (FIG. 2) configuredto display information from the data signals from the adaptor 30 and/orthe disposable loading unit 40 to a user of the surgical instrument 10.

Referring now to FIGS. 2-5, the handle 20 is operatively associated withan energy source 24 that provides energy to the handle 20 and theadaptor 30. It is within the scope of this disclosure that the handle 20includes a first energy source for the handle 20 and a second energysource for the adaptor 30. The energy source 24 may be disposed withinthe handle 20 or disposed external to the handle 20. The energy source24 may be a battery, a wall outlet, or an electrosurgical generator. Theenergy source 24 is electrically connected to a proximal coil 52 of theelectrical interface 50 to provide the proximal coil 52 with asubstantially constant supply of energy. The energy source 24 may bedirectly wired to the proximal coil 52.

The adaptor receiver 26 of the handle 20 includes a protrusion 27extending distally therefrom. The proximal coil 52 of the electricalinterface 50 is disposed within the protrusion 27 of the handle 20. Theadaptor receiver 26 may include one or more drive shafts 23 configure tomechanically manipulate (e.g., rotate or translate) internal componentsof the adaptor 30.

The handle connector 32 of the adaptor 30 includes one or more inputshafts 33 extending therefrom, and defines a recess 34 formed therein.The input shafts 33 are configured to non-rotatably interface with theone or more drive shafts 23 of the handle 20. The handle connector 32 ofthe adaptor 30 includes a distal coil 54 of the electrical interface 50that is positioned adjacent the recess 34. The recess 34 of the adaptor30 is sized and configured to receive the protrusion 27 of the handle20.

The distal coil 54 or the electrical interface 50 is electricallyconnected to an energy storage device 56 of the adapter 30 to provideenergy, typically as a constant current, to the energy storage device 56as detailed below. The energy storage device 56 of the handle 20 isconfigured to energize a plurality of sensors 55 of the adaptor 30. Theenergy storage device 56 may be a capacitor, a capacitive circuit, or abattery.

The plurality of sensors 55 are disposed about the adaptor 30 to detectvarious conditions of the adaptor 30 or of the environment (e.g., ifloading unit is connected, if the adaptor 30 is connected to a handle,if the drive shafts 23 are rotating, the torque of the drive shafts 23,the temperature within the adaptor 30, etc.). The plurality of sensors55 provides input to a data signal processor 57 in the form of datasignals. The data signals may be digital or analog signals. The datasignal processor 57 may be a voltage to current converter that convertsdata signals of the plurality of sensors to high frequency signals fortransmission across the electrical interface 50, as detailed below. Thedata signal processor 57 transmits the data signals to the distal coil54 of the adaptor 30. It is contemplated that the data signal processor57 may be directly wired to the distal coil 54.

With reference to FIGS. 3 and 6, when the handle connector 32 of theadaptor 30 is received within the adaptor receiver 26 of the handle 20,the recess 34 receives the protrusion 27. When the recess 34 of theadaptor 20 is received within the protrusion 27 of the handle 20, theproximal and distal coils 52, 54 form a data transformer 58 towirelessly transfer energy (e.g., inductively transfer) from theproximal coil 52 to the distal coil 54 and to wirelessly transfer (e.g.,inductively transfer) the data signals from the distal coil 54 to theproximal coil 52. It will be appreciated that, when the adaptor 30 iscoupled to the handle 20, a gap is defined between the proximal anddistal coils 52, 54.

The energy source 24 of the handle 20 provides energy to the proximalcoil 52. The energy provided by the energy source 24 may be constant orfluctuate at a low frequency (i.e., fluctuate below 100 Hz). It will beappreciated that the high frequency signals fluctuate at a highfrequency (i.e., over 20 KHz) relative to the frequency of anyfluctuation in the energy provided by the energy source 24 to avoidinterference between the provided energy and the high frequency signals.The energy received by the proximal coil 52 is inductively transferredacross the gap and across the data transformer 58 to the distal coil 54.The transferred energy may be stored in the energy storage device 56and/or used to energize components of the adaptor 30 including but notlimited to the data signal processor 57 and the plurality of sensors 55.

The data signals from the plurality of sensors 55 of the adaptor 30 aregenerated as a voltage that is passed through the data signal processor57 of the adaptor 30 before being sent to the distal coil 54. The datasignal processor 57 converts the data signals from the plurality ofsensors to a high frequency signal using voltage to current conversion.The secondary current circuit affords the opportunity to measure theprimary current modulated by R1 to receive signals from the secondarycircuit. The high frequency current signals are inductively transferredacross the gap and across the data transformer 58 (i.e., from the distalcoil 54 to the proximal coil 52). The high frequency signals from theproximal coil 52 may pass through a filter 53 that reconstructs the datasignals of the plurality of sensors 55 from the high frequency signals.The filter 53 may be a high-pass filter that detects the high frequencysignals and reconstructs the data signals from the detected highfrequency signals. The filter 53 may have a low corner frequency tofilter the high frequency signals from fluctuations in the energyprovided by the energy source 24.

The reconstructed data signals are then transmitted to a processor 22disposed within the handle 20, as shown in FIG. 2. The processor 22 maybe electrically coupled or wirelessly coupled to the display 25 of thehandle 20 and configured to transmit information from the data signalsof the sensors 55 to the display 25. It is contemplated that theprocessor 22 and/or the display are remote to the surgical instrument10. When the processor 22 is remote to the surgical instrument 10, thereconstructed data signal may be transmitted wirelessly from the handle20 to the processor 22.

The handle 20 may include a control interface 21 for activating variouscomponents of the adaptor 30 or loading unit 40. The control interface21 is in electrical communication with the processor 22 to provide inputfrom a user to the processor 22. The processor 22 may wirelesslytransmit (e.g., inductively transfer) control signals to the adaptor 30or loading unit 40 based on the input from the control interface 21and/or the reconstructed data signals (e.g., real-time feedback from theoperation of the surgical instrument 10). The control signals may bedigital or analog signals.

The electrical interface 50 may include a control circuit 60 fortransmitting the control signals. The control circuit 60 includes aproximal control coil 62 and a distal control coil 64 which form acontrol transformer 68 when the handle connector 32 of the adaptor 30 isreceived within the adaptor receiver 26 of the handle 20. The proximalcontrol coil 62 is disposed within the protrusion 27 of the handle 20adjacent to but electrically shielded from the proximal coil 52. Thedistal control coil 64 is positioned adjacent to the recess 34 of theadaptor 30 and to the distal coil 54 but is electrically shielded fromthe distal coil 54. It will be appreciated that the control transformer68 is electrically shielded or isolated from the data transformer 58such that the data signals do not interfere with the control signals.

The control signals from the processor 22 of the handle 20 aretransmitted to a control signal processor 67 thereof. The control signalprocessor 67 is substantially similar to the data signal processor 57and converts the control signals from the processor 22 to high frequencycontrol signals for transmission across the control transformer 68. Thehigh frequency control signals are transmitted from the control signalprocessor 67 to the proximal control coil 62. The proximal control coil62 receives energy from the energy source 24 of the handle 20. It isalso contemplated that the proximal control coil 62 receives energy froma separate and distinct energy source (not shown). The energy receivedby the proximal control coil 62 is inductively transferred across thecontrol transformer 68 to the distal control coil 64.

The high frequency control signals are inductively transmitted acrossthe control transformer 68 from the proximal control coil 62 to thedistal control coil 64. The distal control coil 64 transmits the highfrequency control signals to the control filter 63 that detects the highfrequency control signals within the energy transmitted across thecontrol transformer 68 and reconstructs the control signals therefrom.The reconstructed control signals are then transmitted to variouscomponents of the adaptor 30 and/or the loading unit 40.

Referring to FIG. 7, the surgical instrument 10 may include anelectrical interface 80 formed between the loading unit receiver 36 ofthe adaptor 30 and the loading unit connector 42 of the loading unit 40.The electrical interface 80 is substantially similar to the electricalinterface 50, as such, for reasons of brevity, electrical interface 80will not be detailed herein. The electrical interface 80 is anon-contact interface that inductively transfers energy from the adaptor30 to the loading unit 40 and inductively transfers data signals fromthe loading unit 40 to the adaptor 30. It is also contemplated that theelectrical interface 80 includes a control circuit 90 that inductivelytransfers control signals from the adaptor 30 to the loading unit 40substantially similar to the control circuit 60 detailed above, as suchfor reasons of brevity control circuit 90 will not be detailed herein.The electrical interface 80 may transmit and receive signals (e.g., datasignals and control signals) from the electrical interface 50 and/or theprocessor 22.

With additional reference to FIG. 2, the loading unit 40 may alsoinclude a plurality of sensors 85 disposed thereabout. The plurality ofsensors 85 of the loading unit 40 are substantially similar to theplurality of sensors 55 of the adaptor 30 and are configured to detectvarious conditions of the loading unit 40 or of the environment (e.g.,if the end effector 140 (FIG. 2) is open, thickness of tissue within theend effector 140, the temperature within the loading unit 40, etc.). Theplurality of sensors 85 provides input to the electrical interface 80 inthe form of data signals.

It is also contemplated that a surgical instrument (not shown) includesonly a handle substantially similar to handle 20 and a disposableloading unit substantially similar to disposable loading unit 40connectable to the handle 20 (i.e., no adaptor 30 is used). The surgicalinstrument may include an electrical interface substantially similar tothe electrical interface 50 disposed within the handle and thedisposable loading unit to transmit energy from the handle to thedisposable loading unit and to transmit data signals from the disposableloading unit to the handle.

The wireless transmission detailed herein may be radio frequency,optical, WIFI, Bluetooth® (an open wireless protocol for exchanging dataover short distances (using short length radio waves) from fixed andmobile devices, ZigBee® (a specification for a suite of high levelcommunication protocols using small, low-power digital radios based onthe IEEE 802.15.4-2003 standard for wireless personal area networks(WPANs)), etc.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Any combination ofthe above embodiments is also envisioned and is within the scope of theappended claims. Therefore, the above description should not beconstrued as limiting, but merely as exemplifications of particularembodiments. Those skilled in the art will envision other modificationswithin the scope and spirit of the claims appended hereto.

What is claimed:
 1. A surgical instrument comprising: a handle; anadaptor including a proximal end releasably coupled to a distal end ofthe handle; a loading unit including a proximal end releasably coupledto a distal end of the adaptor; and a non-contact electrical interfaceconfigured to wirelessly transfer energy from the handle to the adaptorand configured to wirelessly transmit data from the adaptor to thehandle.
 2. The surgical instrument of claim 1, wherein the handleincludes a protrusion, wherein the adaptor defines a recess thatreceives the protrusion when the adaptor is coupled to the handle, andwherein the electrical interface includes a proximal electrical coildisposed within the protrusion and a distal electrical coil disposedwithin the adaptor at a location adjacent the recess.
 3. The surgicalinstrument of claim 2, wherein when the adaptor is coupled to the handlethe proximal and distal electrical coils form a transformer.
 4. Thesurgical instrument of claim 2, wherein the proximal electrical coilinductively transfers energy to the distal electrical coil, and thedistal electrical coil inductively transmits data to the proximalelectrical coil.
 5. The surgical instrument of claim 2, wherein theproximal electrical coil inductively transfers a constant supply ofenergy to the distal electrical coil.
 6. The surgical instrument ofclaim 5, wherein the handle includes an energy source disposed therein,wherein the energy source is electrically coupled to the proximalelectrical coil.
 7. The surgical instrument of claim 6, wherein theadaptor includes an energy storage device disposed therein, wherein theenergy storage device is electrically coupled to the distal electricalcoil, and wherein the energy storage device is configured to storeenergy from the energy source.
 8. The surgical instrument of claim 7,wherein the electrical interface includes a signal processor disposedwithin the adaptor, and wherein the energy storage device is configuredto energize the signal processor.
 9. The surgical instrument of claim 4,wherein the electrical interface includes a signal processor disposedwithin the adaptor, the signal processor configured to create highfrequency signals from data signals and transmit the high frequencysignals to the distal electrical coil.
 10. The surgical instrument ofclaim 9, wherein the electrical interface further includes a pluralityof sensors disposed within the adaptor, the plurality of sensorsconfigured to generate and transmit data signals to the signalprocessor.
 11. The surgical instrument of claim 10, wherein the energystorage device is configured to energize the plurality of sensors. 12.The surgical instrument of claim 9, wherein the electrical interfaceincludes a filter disposed within the handle, wherein the filter iselectrically coupled to the proximal electrical coil, and wherein thefilter is configured to reconstruct the data signals from the highfrequency signals.
 13. The surgical instrument of claim 12, wherein thehandle includes a display configured to display information from thereconstructed data signals to a user.
 14. The surgical instrument ofclaim 2, wherein the electrical interface includes a control circuitconfigured to wirelessly transmit control signals from the handle to theadaptor.
 15. The surgical instrument of claim 14, wherein the controlcircuit includes a proximal control coil disposed within the protrusionand a distal control coil disposed within the adaptor at a locationadjacent to the recess, the proximal and distal control coils forming acontrol transformer when the adaptor is coupled to the handle toinductively transmit control signals from the handle to the adaptor. 16.The surgical instrument of claim 15, wherein the handle includes acontrol interface and the electrical interface includes a processordisposed within the handle, the processor configured to receive controlinputs from the control interface and to receive data from the adaptor,the processor configured to generate control signals from the controlinputs and from the data, the processor configured to transmit thecontrol signals to the proximal control coil.
 17. The surgicalinstrument of claim 1 further comprising a loading unit releasablycoupled to a distal end of the adaptor and to form a second electricalinterface, the second electrical interface configured to inductivelytransfer energy from the adaptor to the loading unit and configured toinductively transmit data signals from the loading unit to the adaptor.18. A method of communication between components of a surgicalinstrument, the method comprising: providing a surgical instrumentincluding a handle, a loading unit, and an adaptor; coupling a proximalend of the adaptor to a distal end of the handle to form a non-contactelectrical interface therebetween; coupling a proximal end of theloading unit to a distal end of the adaptor; using the non-contactelectrical interface to wirelessly transfer energy from an energy sourcedisposed within the handle to the adaptor; and using the non-contactelectrical interface to wirelessly transmit data from the adaptor to thehandle.
 19. The method of claim 18, wherein forming the non-contactelectrical interface includes positioning a proximal coil disposedwithin the handle adjacent a distal coil disposed within the adaptor toform a transformer, wirelessly transferring energy from the energysource includes inductively transferring energy across the transformerfrom the handle to the adaptor, and wirelessly transmitting data fromthe adaptor to the handle includes inductively transmitting data acrossthe transformer from the adaptor to the handle.